Workshop Manual
Octavia II 2004 ➤ , Octavia II 2010 ➤ ,
Superb II 2008 ➤ , Superb II 2011 ➤ ,
Yeti 2010 ➤ , Yeti 2011 ➤
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine
CDA CDA CCZ
Engine ID BZB A B A
Edition 04.2014
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety measures to apply when working on the fuel injection and ignition system . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules of cleanliness to observe when working on the fuel supply system . . . . . . . . . . . . . . 5
3.2 Release pressure in the high pressure area of the fuel system . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Additional instructions when undertaking assembly work on the air-conditioning system . . 8
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1 V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Removing and installing tensioner pulley for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.5 Removing and installing ribbed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 Cylinder block - gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Sealing flange and flywheel - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Removing and installing the sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . 42
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1 Crankshaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2 Assign crankshaft bearing shells to the cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Pulling out and driving in the needle bearing of the crankshaft . . . . . . . . . . . . . . . . . . . . . . 48
3.4 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3 Inspect piston, piston rings and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Contents i
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Oil sump and oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Oil sump and oil pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Removing and installing oil sump bottom part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.4 Removing and installing oil sump top part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2 bracket for auxiliary units with oil filter and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 145
2.1 Bracket for auxiliary units with oil filter and engine oil cooler - Summary of components . . 145
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.3 Removing and installing oil pressure switch F1/F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.4 Removing and installing oil pressure switch F378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.5 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.1 Parts of cooling system on the side next to the body - Summary of components . . . . . . . . 152
1.2 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2 Pumps, coolant regulators, coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Coolant recirculation pump V51 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Removing and installing coolant recirculation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.3 Coolant pipe - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.4 Removing and installing the front coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.5 Removing and installing small coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.6 The coolant pump and coolant regulator - List of assembly parts . . . . . . . . . . . . . . . . . . . . 164
2.7 Replace coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.8 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.9 Replace radial shaft seal for coolant pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.10 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.11 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.1 Removing and installing fan shroud for radiator fan V7 and V35 . . . . . . . . . . . . . . . . . . . . 176
3.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
ii Contents
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.3 Check proper operation of pressure box for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.4 Removing and installing the exhaust gas turbocharger pressure box . . . . . . . . . . . . . . . . 235
1.5 Adjusting exhaust turbocharger pressure box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.1 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.2 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.4 Connection diagram for turbocharger charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.5 Hose connections of the charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.6 Checking the charge-air system with turbocharger for leaktightness . . . . . . . . . . . . . . . . . . 245
Contents iii
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
iv Contents
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
00 – Technical data
1 Denomination
(SRL000687; Edition 04.2014)
Note
The four digit engine code is on the vehicle data sticker ⇒ Main‐
tenance ; Booklet Octavia II/Superb II/Yeti and on the engine
control unit.
1. Denomination 1
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
2 Safety instructions
WARNING
Caution
When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel!
♦ Wear fuel-resistant gloves!
2. Safety instructions 3
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
WARNING
3 Repair instructions
WARNING
Note
3. Repair instructions 5
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
WARNING
The fuel lines are pressurized! Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.
Before opening the high pressure area, lay cleaning cloths
around the connection point.
Note
WARNING
Caution
3. Repair instructions 7
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
♦ Before screwing down the oil feed line, fill the exhaust turbo‐
charger via the connection fitting with engine oil.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.
WARNING
Note
Note
Caution
Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 3 .
– Remove air filter housing ⇒ page 271 .
– Press the release buttons and remove pipe -2- for crankcase
ventilation.
– Unscrew plug -arrow-.
– Loosen hose clamp -1- and remove the intake manifold.
Note
– Release duct for engine wiring harness -arrow- and pull out
upwards.
– Expose the left engine wiring harness at the rear on the bulk‐
head plenum chamber.
Caution
WARNING
Caution
– Disconnect plug -1- for oil level and oil temperature sender -
G266- .
– Unclip the mounting bracket -2- for the electrical cable to the
oil level and oil temperature sender - G266- at the assembly
bracket.
– Remove/unclamp all other necessary electrical cables from
the engine/gearbox unit, and expose them.
– Unclamp all connecting, coolant, vacuum and suction hoses
from the engine.
– Secure the engine mount -T10359- with the bolt -1- to the cyl‐
inder block with a torque of approx 20 Nm.
Note
The threaded bore for the bolt -1- is used to tighten the coolant
recirculation pump - V51- .
Note
Use double ladder - VAS 5085- to release the screws for the as‐
sembly bracket.
Note
Work procedure
– Drive the engine with gearbox with the engine and gearbox
jack - V.A.G 1383 A- to a work bench
– Lower the engine/gearbox unit in such a way that the gearbox
is positioned on the support.
– Remove engine/gearbox connecting screws.
– Press gearbox from engine.
– Suspend the lifting device - MP 9-201- as follows and remove
the engine from the engine mount - T10359- using the work‐
shop crane .
WARNING
Use securing pins on the hooks and rig pins in order to avoid
injuries and damage to the engine.
Caution
Note
Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 3 .
– Insert new dowel sleeves for centering the engine/transmis‐
sion into the cylinder block.
– Ensure that the intermediate plate has been inserted on the
sealing flange and is pushed onto the dowel sleeves
-arrows-.
For vehicles with manual gearbox
– Check the centering of the clutch disc ⇒ Gearbox; Rep. gr.
30 .
– Check clutch release bearing for wear and renew if necessary.
– Checking and installing clutch and clutch control.
– Lightly lubricate spline of input shaft with grease - G 000 100- .
For vehicles with automatic gearbox DSG
Note
Tightening torques
Component Nm
Screws and nuts M6 9
M7 13
M8 20
M10 40
M12 70
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. gr. 34
Screws for assembly bracket ⇒ page 22 .
2 Assembly bracket
12 - Bolts
❑ replace
❑ on manual gearbox MQ350 (02Q) check if threaded inserts (e.g. Heli-Coil), have been installed in the
thread ⇒ page 23
❑ if threaded inserts are not installed, they must be subsequently installed (Part No. 02Q.301.561), other‐
wise there is the risk of the threads shearing
❑ 50 Nm + torque a further 90° (1/4 turn)
13 - Bolts
❑ replace
14 - Bolts
❑ replace
❑ 40 Nm + torque a further 90° (1/4 turn)
15 - Gearbox mount
16 - Gearbox support bracket
17 - Screw
❑ Tightening torque ⇒ Gearbox; Rep. gr. 34
Note
The distance -x- can be checked, for example with suitable round
bars.
2. Assembly bracket 23
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Note
The distance -x- can be checked, for example with suitable round
bars.
– Make sure that on the gearbox side the edges of the support‐
ing arm -2- and gearbox support -1- are parallel.
• The dimension -x- must be the same on both mount sides.
– Tighten the screws for the gearbox side assembly bracket
⇒ page 22 .
Installation is carried out in the reverse order.
2. Assembly bracket 25
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Note
The distance -x- can be checked, for example with suitable round
bars.
– Make sure that on the gearbox side the edges of the support‐
ing arm -2- and gearbox support -1- are parallel.
• The dimension -x- must be the same on both mount sides.
– Tighten the screws for the gearbox side assembly bracket
⇒ page 22 .
Installation is carried out in the reverse order.
13 – Crankshaft group
1 Cylinder block (pulley end)
9 - Screw
❑ 23 Nm
10 - Screw
❑ replace
❑ order of tightening ⇒ page 28
❑ 20 Nm + torque a further 90° (1/4 turn)
11 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
12 - Screw
❑ 25 Nm
13 - Fitting sleeve
❑ for the AC compressor
Caution
Note
– Insert the tensioner pulley -1- for bracket for auxiliary units into
the bracket for auxiliary units -3- and tighten the screw -5-.
• Pay attention to the fitting location of the support piece -2- :
Insert the peg of the support piece into the bore on the bracket
for auxiliary units.
• Note the dowel sleeve -4-.
– Install poly V-belt ⇒ page 28 .
– Install pump for coolant recirculation - V51- ⇒ page 159 .
– Adjusting the assembly bracket:
♦ Octavia II, Yeti ⇒ page 23
♦ Superb II ⇒ page 25
WARNING
Caution
Note
Note
Fixing screw for crankshaft belt pulley -A- joins the belt pulley
-1-, the sprocket on the timing belt -2 - and the crankshaft -3-.
Before removing the fixing screw, the crankshaft chain sprocket
must be secured as shown.
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Undo the screw for the belt pulley by 1/2 turn with the coun‐
terholder - T10355- . The belt pulley must be in the OT position.
– Fit the assembly tool - T10531/1- and firmly secure with the
hand using knurled screws, as shown in the figure.
– Remove the screw for the V-ribbed belt pulley crankshaft.
Note
– Put the V-ribbed belt pulley crankshaft into the TCD position,
note the tooth contour of the chain wheel -arrow-.
– Fit the assembly tool - T10531/1- and firmly secure with the
hand using knurled screws, as shown in the figure.
– Screw in new screw for the V-ribbed belt pulley crankshaft with
the new O-ring -1- by hand.
– Replace the screw for the V-ribbed belt pulley crankshaft with
counterholder - T10355- .
Note
Engine removed
– Position the flywheel lock - MP 1-504- on the starter ring gear
of the flywheel and turn crankshaft until the lock rests against
the sleeve - T30010 - .
Caution
Note
WARNING
Note
Note
After installing the sealing flange on the gearbox side, allow the
sealant to dry for about 30 minutes. Only then may engine oil be
filled in.
3 Crankshaft
Note
If considerable quantities of metal swarf or abrasion is found when carrying out engine repairs, this can be
subject to damage to the crankshaft and conrod bearings. In order to avoid consequential damage, after the
repair perform the following tasks:
1 - Cylinder block
❑ if the cylinder block is re‐
placed, the bearing
shells in the cylinder
block will need to be re-
assigned ⇒ page 47
2 - Bearing shell for cylinder
block
❑ with lubricating groove
❑ do not mix up used bear‐
ing shells (mark)
❑ Identification
⇒ page 47
3 - Crankshaft
❑ New axial clearance:
0.07 … 0.23 mm
Wear limit: 0.30 mm
❑ ∅ Crankshaft bearing
journal:
♦ 1.8 l engines: 52.00 mm
♦ 2.0 l engines: 58.00 mm
❑ ∅ Conrod bearing jour‐
nal: 47.80 mm
❑ install the crankshaft af‐
ter removal so that the
sensor rotor -Pos. 8-
dos not rest or is dam‐
aged.
❑ if the crankshaft is re‐
placed, the bearing
shells for the bearing
covers will need to be
re-assigned
⇒ page 47
❑ the needle bearing is mounted on vehicles with automatic transmission DSG
❑ Pulling out and driving in the needle bearing for crankshaft ⇒ page 48
4 - Bearing shell for bearing cap
❑ without lubricating groove
3. Crankshaft 45
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
❑ do not mix up used bearing shells (mark)
❑ Identification ⇒ page 47
5 - Screw
❑ replace
❑ order of tightening ⇒ page 47
6 - Bearing caps
❑ Bearing cover 1: Belt pulley side
❑ retaining lugs of the bearing shells of the cylinder block/bearing cap must be on top of one another
7 - Screw
❑ replace
❑ Replace sensor rotor every time the bolts are slackened
❑ 10 Nm + torque a further 90° (1/4 turn)
8 - Rotor
❑ For engine speed sender - G28- .
❑ Replace sensor rotor every time the bolts are slackened
❑ assembly only possible in one position -holes offset-
❑ removing and installing ⇒ page 46
9 - Thrust washers
❑ for bearing 3
10 - Screw
❑ replace
❑ order of tightening ⇒ page 47
Note
– Always replace the sensor rotor -2- each time the bolts -1- are
slackened.
Note
3. Crankshaft 47
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
The indication on the cylinder block applies for the upper bearing
shell (bearing shell for cylinder block).
– Note down the letters and look for the colour indication to be
installed using the table.
Crankshaft
Note
Condition:
• If the engine and transmission were separated, always replace
the needle bearing -arrow-.
• The leading edges of the internal extractor must not have bro‐
ken out.
Extraction
3. Crankshaft 49
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Note
If the needle bearing is driven into too deep it will need replacing
as it is damaged when pulling it out.
1 - Conrod bolt
❑ replace
❑ Oil thread and contact
surface
❑ M8: 30 Nm + torque a
further 90° (1/4 turn)
❑ M9: 45 Nm + torque a
further 90° (1/4 turn)
2 - Conrod bearing cap
❑ Check fitting position
❑ as a result of the con‐
rods separated in the
cracking process, the
cover fits only in one po‐
sition and only to the rel‐
evant conrod
❑ mark matching cylinder
-A-
❑ Fitting position: Mark‐
ings -B- point towards
belt pulley side
3 - Bearing shells
❑ pay attention to correct
installation position
⇒ page 52
❑ oil before the assembly
❑ Do not interchange
used bearing shells.
❑ New axial clearance:
0.10 … 0.35 mm
Wear limit: 0.4 mm
Note
Inspecting pistons
Note
Note
1 - O-ring
❑ replace
❑ oil before the assembly
2 - Guide tube for oil dipstick
3 - Screw
❑ 9 Nm
4 - Screw
❑ 9 Nm
5 - Inlet camshaft control valve
1 - N205 -
6 - Sealing ring
❑ oil before the assembly
❑ replace if damaged
7 - Screw
❑ Screw captive
❑ order of tightening
⇒ page 57
❑ 9 Nm
8 - Install top cover for timing
chain
❑ removing and installing
⇒ page 57
9 - Gasket
❑ oil before the assembly
❑ replace if damaged
10 - O-ring
❑ replace
❑ oil before the assembly
11 - Dowel pins
❑ Centre cover
12 - Install top cover for timing chain
❑ removing and installing ⇒ page 58
13 - Screw
❑ replace
❑ order of tightening ⇒ page 58
❑ 8 Nm + torque a further 45° (1/8 turn)
14 - Sealing ring
❑ for crankshaft
❑ replace ⇒ page 63
15 - Plug
❑ replace
– Unscrew the screws for the guide pipe for dipstick -arrows-.
– Remove valve-1- for camshaft control - N205- ⇒ page 127 .
– Undo screws -1 - to -5- and remove the top cover for the timing
chain.
Note
Install
– Tighten the screws for the guide pipe for dipstick -arrows-.
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
• Tightening torques: ⇒ page 56
– Unscrew the screws -arrows- and remove guide pipe for dip‐
stick from the bottom cover for timing chain.
Note
WARNING
Note
– Check whether both fitted pins -arrows- are present for cen‐
tering the bottom cover for timing chain.
Note
♦ The bottom cover for the timing chain must be installed within
5 minutes after applying the sealant.
♦ The sealant bead must not be thicker than specified otherwise
excess sealant may get into the oil pan and clog the strainer
in the oil suction pipe.
– Fit bottom cover for timing chain immediately and tighten the
new screws -1 to 15- in 2 steps in the sequence shown:
1. Tighten screws to 8 Nm.
2. Screw a further 45° (1/8 turn)
Note
Note
Always use a new gasket ring. Moisten with oil before the as‐
sembly.
– Insert the gasket ring -arrow- with thrust piece - T10354- into
the timing case.
1 - Screw
❑ 9 Nm
2 - Chain tensioner
❑ is under spring tension
❑ Depending on the ver‐
sion, and before disas‐
sembly, remove rig pin -
T40011- or extractor -
T40267-
3 - Tensioning rail
4 - Guide bolt, 20 Nm
5 - Screw
❑ 9 Nm
6 - Control valve, 35 Nm
❑ Left-hand thread
❑ for engine identification
characters BZB, re‐
move with assembly
tool - T10352-
❑ for engine identification
8 - Washer
9 - Bearing frame
10 - Sliding rail
11 - Cylinder head cover
12 - Camshaft timing shaft
❑ mark the direction of rotation in colour before removing
❑ removing and installing ⇒ page 66
13 - Sliding rail
14 - Guide bolt
❑ 20 Nm
15 - Sprocket
❑ at the crankshaft
❑ Fitting position ⇒ page 66
Caution
Caution
Note
Note
Before installing the tensioning rail, you must check that the col‐
oured chain link still covers the crankshaft marking.
– Check the position of the of the coloured chain links with re‐
spective to the markings.
– Install the final drive chain between the oil pump and chain
tensioner.
Note
♦ The figure shows the engine with a cover mounted below for
the timing belt.
♦ Depending on the transmission ratio, the coloured chain links
may no longer overlap after rotating the engine. For this rea‐
son, check the timing with dial gauge.
Note
– Measure the distance from the left outer edge of the ledge
-A- to the marking -B- on the inlet camshaft.
• Specified value: 61 … 64 mm
Note
1 - Screw
❑ 9 Nm
2 - Balancing shaft
❑ Replace after disas‐
sembly
❑ Outlet side
❑ Oil bearing with engine
oil
❑ removing and installing
⇒ page 83
3 - Pipe for balancing shaft
❑ Fitting position
⇒ page 77
4 - Chain tensioner
❑ install with sealant ⇒
ETKA - Electronic Cata‐
logue of Original Parts
❑ 85 Nm
5 - Cylinder block
6 - Balancing shaft
❑ Replace after disas‐
sembly
❑ Inlet side
❑ Oil bearing with engine
oil
❑ removing and installing
⇒ page 80
7 - O-ring
❑ wet with engine oil
8 - Bearing bolt
❑ wet with engine oil
❑ Fitting position ⇒ page 77
9 - Intermediate shaft wheel
❑ for balancing shaft
❑ When the bolt -Pos. 11- was undone, the intermediate shaft wheel must be replaced due to the clearance
on the toothed flank.
❑ Fitting position ⇒ page 78
10 - Screw
❑ 9 Nm
11 - Washer
12 - Screw
❑ replace
❑ When undoing the screw, the intermediate shaft wheel -Pos. 9- must be replaced.
Caution
Note
Note
Note
Removing
– Remove toothed belt pulley for coolant pump ⇒ page 167 .
– removing balancing shaft timing chain ⇒ page 78 .
– Remove intermediate shaft wheel -1-.
– Screw the puller - T10055- into the puller - T10394- and deflect
the balancing shaft in the -direction of arrow-.
Install
Note
– Install the balancing shaft for inlet camshaft and tighten the
screw -2-.
Caution
Note
Note
Removing
– removing balancing shaft timing chain ⇒ page 78 .
– Remove balancing shaft for exhaust camshaft -1-.
If the balancing shaft cannot be removed by hand, use the ex‐
tractor - T10394- :
– Screw the puller - T10055- into the puller - T10394- and deflect
the balancing shaft in the -direction of arrow-.
Install
Note
Note
To bring the pipe into the assembly position, this must be pressed
together somewhat. Press the pipe into the crankcase and bend
both halves once towards the inside.
Note
If the balancing shaft does not rest plane, the pipe for the balanc‐
ing shaft will need to be refitted.
4 Cylinder head
Note
8 - Plug
9 - to the intake manifold/tur‐
bocharger
10 - Ventilation tube
11 - O-ring
❑ no spare part
12 - Sealing ring
❑ no spare part
13 - Screw
❑ Note the tightening sequence for crankcase ventilation ⇒ page 88
❑ 11 Nm
14 - Crankcase ventilation
15 - To intake manifold
16 - Gasket
❑ no spare part
17 - Screw
❑ Tightening torques with the engine with identification characters BZB: 9 Nm
❑ Tightening torques with the engine with identification charactersCDAA,CDAB,CCZA: 8 Nm + torque a
further 180° (1/2 turn)
18 - Vacuum pump
❑ removing and installing ⇒ page 109
❑ do not disassemble vacuum pump
19 - Gasket
❑ replace
20 - Screw
❑ 9 Nm
21 - Inlet connections
22 - O-ring
❑ replace
❑ Moisten with coolant
23 - Screw
❑ 25 Nm
24 - Lifting eye - on the left
25 - Screw
❑ 9 Nm
26 - Hall sender - G40-
27 - Divider plate
28 - Screw
❑ 25 Nm
29 - Lifting eye - on the right
4. Cylinder head 87
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
4. Cylinder head 89
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Note
– Press the release buttons and remove pipe -2- for crankcase
ventilation.
– Release screw -arrow-.
– Loosen hose clamp -1- and remove the intake manifold.
Note
– Remove the connector from the ignition coils and place the
wiring harness to one side.
– Remove ignition coils with extractor - T40039- ⇒ page 302 .
4. Cylinder head 91
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1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
– Remove the vacuum hose -1- from the vacuum pump and ex‐
pose.
– Disconnect the vacuum hose from the turbocharger at the
connecting stud underneath the position -1-.
– Unscrew earth strap -2-.
– Expose the wiring harness of the connector -3-.
– Remove the coolant hoses -4- and -5- .
– Remove coolant hose from connection fitting of the cylinder
head.
– Unscrew screws -1- to -3- (20 Nm) and remove the heat shield
together with the coolant pipe.
– Unscrew the screw -4- for the oil feed line to the turbocharger.
Note
Remove screw -2- from the heat shield using an adapter with 6
mm hex -A-. The form of the hexagon must be at least 5 cm -B-.
The adapter which narrows to 6 mm at the tip, is too thick.
4. Cylinder head 93
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
– Unscrew the nuts -1-, unscrew the screw -2- and remove the
intake manifold support.
Caution
4. Cylinder head 95
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Caution
4. Cylinder head 97
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
– Remove top sliding rail -1-. To do so, unlock the catch using
a screwdriver and push off the sliding rail from the cylinder
head cover.
– Mark the position of the chain sprockets -arrow- for the locking
devices with a felt-tip pin.
– Remove the camshaft timing shaft from the chain sprockets
and lay downwards.
Note
When the bottom cover for timing chain is assembled, the looser
chain “can” “not” jump the crankshaft.
Caution
Risk of damaging the valve gear and the bottom cover for tim‐
ing chain!
♦ When the camshaft timing shaft was removed from the
chain sprockets, the crankshaft must not be turned further.
♦ Plates are attached to the bottom cover for timing chain
which prevents the chain from slipping. When the crank‐
shaft is rotated when the chain is more loose, the plates
may bend.
Note
4. Cylinder head 99
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Caution
Note
– Measure the distance from the left outer edge of the ledge
-A- to the marking -B- on the inlet camshaft, and note down
the value.
– Compare the distance from the left outer edge of the ledge
-A- to the marking -B- with the value noted down.
Note
– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
WARNING
– Suspend the cylinder head from the workshop crane and po‐
sition it above the cylinder block.
Caution
Note
To be able to screw the cylinder head bolts, rotate the inlet cam‐
shaft with the key.
– Check and turn the V-ribbed belt pulley, crankshaft with the
counterholder - T10355- in position “ODT for cylinder 1”
-arrow-.
• The notch on the V-ribbed belt pulley must face the arrow
marking on the bottom cover for the timing chain.
Note
– Continue the hold the camshaft in place, and install the ten‐
sioning rail for camshaft timing shaft. Tighten the screw -A-.
– Remove the camshaft fixer/locator - T40271/1- .
Note
– Mount the bearing frame (do not tilt) and screw in screws
-arrows- by hand.
– Depending on the version, remove the rig pin - T40011- or
extractor - T40267- .
Caution
Test sequence
– Remove the ignition coils with power output stages and the
spark plugs ⇒ page 302 .
– Open lid of the e-box in the engine compartment and unplug
the fuse for Motronic - J271 - ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations current supply relay.
Note
Note
If the specified values are not reached, test the combustion cham‐
ber for tightness ⇒ page 108 .
Installation occurs in reverse order to removal. However, pay at‐
tention to the following:
– Install ignition coils ⇒ page 302 .
– Delete the contents of the fault memory for the engine control
unit at the end of the work as error messages were stored due
to disconnecting the plugs ⇒ Vehicle diagnostic tester.
Note
5 Valve gear
Note
♦ Cylinder head and cylinder head cover may only be used to‐
gether.
♦ After installing the camshafts, the engine must not be started
for about 30 minutes. The hydraulic clearance compensation
elements must settle (otherwise valves would strike the pis‐
tons).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.
♦ Always replace seals and gasket rings.
1 - Exhaust valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ Valve dimensions
⇒ page 112
❑ inspecting valve guides
⇒ page 134
2 - Cylinder head
3 - Valve guide
❑ check ⇒ page 134
4 - Valve stem seal
5 - Valve spring
6 - Valve spring retainer
7 - Valve collets
8 - Hydraulic balancing ele‐
ment
❑ do not interchange
❑ oil contact surfaces
9 - Exhaust camshaft
❑ removing and installing
⇒ page 112
❑ Slack: max. 0.04 mm
10 - Cylinder head cover
❑ with integrated cam‐
shaft bearing
❑ removing and installing
⇒ page 112
❑ Clean the sealing surfa‐
ces- do not rework
❑ remove old sealant residues
11 - Bolts
❑ replace
Note
Make sure that the cylinder head cover does not tilt.
Valve dimensions
Note
Note
♦ The sealing surfaces of the lower cylinder head cover and the
top cylinder head must not be machined.
♦ The camshaft bearings are integrated in the cylinder head/
cylinder head cover. Before removing of the cylinder head
cover, the camshaft timing shaft must be relieved.
♦ If the cylinder head cover was loosened, the screw cap must
be replaced between the cylinder head cover and the cylinder
head.
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 50 .
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
Vehicles with auxiliary heating
– Unscrew clamp -1- and remove screw -2-.
– Remove the muffler for the auxiliary heating.
Continued for all vehicles
Caution
Caution
– Remove top sliding rail -1-. To do so, unlock the catch using
a screwdriver and push off the sliding rail from the cylinder
head cover.
– Mark the position of the chain sprockets -arrow- for the locking
devices with a felt-tip pin.
– Remove the camshaft timing shaft from the chain sprockets
and lay downwards.
Note
When the bottom cover for timing chain is assembled, the looser
chain “can” “not” jump the crankshaft.
Caution
Risk of damaging the valve gear and the bottom cover for tim‐
ing chain!
♦ When the camshaft timing shaft was removed from the
chain sprockets, the crankshaft must not be turned further.
♦ Plates are attached to the bottom cover for timing chain
which prevents the chain from slipping. When the crank‐
shaft is rotated when the chain is more loose, the plates
may bend.
Note
– Measure the distance from the left outer edge of the ledge
-A- to the marking -B- on the inlet camshaft, and note down
the value.
– Remove the connector from the ignition coils and place the
wiring harness to one side.
– Remove ignition coils with extractor - T40039- ⇒ page 302 .
– Loosen and remove screws for cylinder head cover in the se‐
quence -1 … 6-.
– Remove cylinder head cover.
– Carefully lift out camshafts and place down on a clean surface.
WARNING
Note
Note
Note
Make sure that the cylinder head cover does not tilt.
– Drive in the screw cap -1- with the thrust piece - T10174- .
-a- = 1…2 mm
Caution
Risk of damaging the valve gear and the bottom cover for tim‐
ing chain!
♦ When turning the crankshaft, the timing chain must be
kept tight by hand.
♦ Plates are attached to the bottom cover for timing chain
which prevents the chain from slipping. When the crank‐
shaft is rotated when the chain is more loose, the plates
may bend.
– Check and turn the V-ribbed belt pulley, crankshaft with the
counterholder - T10355- in position “ODT for cylinder 1”
-arrow-.
• The notch on the V-ribbed belt pulley must face the arrow
marking on the bottom cover for the timing chain.
– Compare the distance from the left outer edge of the ledge
-A- to the marking -B- with the value noted down.
Note
– Continue the hold the camshaft in place, and install the ten‐
sioning rail for camshaft timing shaft. Tighten the screw -A-.
– Remove the camshaft fixer/locator - T40271/1- .
Note
Note
When the markings are not covered on the timing chain and slid‐
ing rail -2-, even the engine stands on the “ODT for cyl. 1”, where
necessary, the drive chain on the chain sprocket may jump the
crankshaft. Test timing ⇒ page 74 . If the timing does not line up,
re-position the camshaft timing shaft from “new” ⇒ page 66 .
– Pull off valve stem seal with extractor for valve stem seal -
3364- .
– Set the lower part of the valve stem seal extractor - 3364- onto
the valve stem seal.
– Insert the mandrel -1- into the bore in the lower part of the
extractor.
– Attach an assembly lever to the extractor and remove the
valve stem seal -arrow-.
WARNING
Inlet side
Outlet side
Note
– Screw on the guide plate for the FSI engine - VAS 5161/19B-
with knurled screws - VAS 5161/12- to the cylinder head as
shown.
– Insert the impact drift -VAS 5161/3- into the guide plate and
knock off the tightly fitted valve collets using a plastic hammer.
– Pull off valve stem seal with extractor for valve stem seal -
MP1-230 (3364)- .
WARNING
Inlet side
Outlet side
Note
Note
17 – Lubrication
1 Oil sump and oil pump
Note
22 - Suction line
❑ Clean strainer if dirty
❑ Pay attention to the part number
23 - O-ring
❑ replace
24 - Sealing ring
❑ replace
25 - O-ring
❑ replace
26 - Non-return valve
27 - Sealing ring
❑ replace
28 - Oil drain plug
❑ 30 Nm
29 - Nut
❑ 9 Nm
Note
WARNING
– Expose sealing surface on upper and lower part of the oil pan
and remove sealant residues with chemical sealant remover.
– Degrease the sealing surfaces.
Note
Note
– Immediately fit the lower part of the oil pan and tighten the new
screws in the sequence -1 to 20- as follows.
1. Tighten screws to 8 Nm.
2. Turn screws 45° further.
Note
After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
– Unscrew the screws -arrows- and swing out the oil pump with
chain sprocket.
Install
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
♦ Tightening torques ⇒ page 135
– Before installing the oil pump, check the sieve in the suction
line and the oil channels in the upper part of the oil sump for
dirt.
– Check whether both dowel sleeves are present for centering
the oil pump.
– Replace baffle.
Note
The baffle has a plastic ribbing which deforms over a longer pe‐
riod of tightening. The plastic ribbing ensures that the baffle sits
tight and does not rattle. For this reason, the baffle must always
be replaced.
Caution
To avoid later seals, do not deform the bottom cover for the
timing chain and, when pushing off the upper part of the oil
sump, do not reach between the screw points.
WARNING
Danger of injury! When removing the upper part of the oil sump,
the spring of the chain tensioner for the oil pump drive jumps
from the upper part of the oil sump to the bottom cover for the
timing chain. While removing the upper part of the oil sump, do
not reach between the upper part of the oil sump and the lower
cover for the timing chain.
– Release screws -1 to 14- and remove the upper part of the oil
sump. If necessary, undo the oil pan by applying slight blows
with a rubber-headed hammer.
Install
WARNING
– Check oil channels in the oil sump top part and in the cylinder
block for contamination.
– Pull the tensioning spring of the chain tensioner for the oil
pump with assembly device - T10118 - in -direction of arrow-
and secure with extractor - T40265- .
Note
Note
♦ The upper part of the oil sump must be installed and tightened
firmly immediately after applying the sealant.
♦ The sealant bead must not be thicker otherwise excess seal‐
ant may get into the oil pan and block the strainer in the oil
pump suction pipe.
– Immediately fit the upper part of the oil pan, align it plane to
the cylinder block on the gearbox side, and tighten the new
screws in the sequence -1 to 14- as follows:
– 1. Tighten screws to 15 Nm.
– 2. Turn screws 90° further.
2.1 Bracket for auxiliary units with oil filter and engine oil cooler - Summary of
components
charactersCDAA,CDAB,CCZA: Oil pressure switch - F22- 0.215 - 0.295 MPa (2.15 - 2.95 bar) blue
❑ check ⇒ page 147
❑ removing and installing ⇒ page 147
❑ Tightening torque: 20 Nm
3 - Oil pressure switch for reduced oil pressure - F378-
❑ only with the engine with identification charactersCDAA,CDAB,CCZA
❑ 0.055 - 0.085 MPa (0.55 - 0.85 bar) brown
❑ check ⇒ page 147
❑ removing and installing ⇒ page 147
❑ Tightening torque: 20 Nm
4 - Gasket
❑ replace
2. bracket for auxiliary units with oil filter and engine oil cooler 145
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
5 - O-ring
❑ a part with valve unit
6 - O-ring
❑ a part with valve unit
7 - valve unit
❑ with O rings
8 - Oil filter
❑ removing and installing ⇒ Maintenance ; Booklet Octavia II/Superb II/Yeti
❑ Remove and install with oil filter tool .
❑ 22 Nm
9 - Screw
❑ 15 Nm
10 - Supports
11 - Sealing ring
❑ replace
12 - Engine oil cooler
❑ pay attention to the notes ⇒ page 135
❑ ensure clearance to surrounding components
❑ connection diagram for coolant hoses ⇒ page 154
❑ removing and installing ⇒ page 146
13 - Gasket
❑ replace
14 - Screw
❑ replace
❑ order of tightening ⇒ page 28
❑ 20 Nm + torque a further 90° (1/4 turn)
Note
– Install the engine oil cooler -3- with a new seal -2-.
Tightening torques: ⇒ page 145
– Install the bracket for auxiliary units ⇒ page 32 .
Note
Install
Installation is carried out in the reverse order. However, pay at‐
tention to the following:
– Renew O-ring.
– Checking the oil level.
• Tightening torques: ⇒ page 145 .
Note
Install
Installation is carried out in the reverse order. However, pay at‐
tention to the following:
– Renew O-ring.
– Checking the oil level.
• Tightening torques: ⇒ page 145 .
2. bracket for auxiliary units with oil filter and engine oil cooler 147
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Note
Functional test and repair of the visual and acoustic oil pressure
display ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations, ⇒ Vehicle diagnostic tester.
– Screw the testing device into the oil filter holder instead of the
removed oil pressure switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594 C- .
• The LED must not light up.
– If the LED lights up, replace the oil pressure switch .
If the LED does not light up:
– Start engine and increase the engine speed.
For engines with identification characters BZB
• The LED must light up at an overpressure of 0.12…0.16 MPa
(1.2...1.6 bar), if not replace oil pressure switch.
For engines with identification charactersCDAA,CDAB,CCZA
• With the oil pressure switch - F22- the voltage tester must in‐
dicate an oil overpressure at 0.215 - 0.295 MPa (2.15 - 2.95
bar) - if not, replace the oil pressure switch.
• With the oil pressure switch for reduced oil pressure - F378-
the voltage tester must indicate an oil overpressure at 0.055 -
0.085 MPa (0.55 - 0.85 bar) - if not, replace the oil pressure
switch.
2. bracket for auxiliary units with oil filter and engine oil cooler 149
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
– Screw the testing device into the oil filter holder instead of the
removed oil pressure switch.
– Start engine and increase the engine speed.
For engines with identification characters BZB
• At 2000 rpm, the oil overpressure is 0.27 … 0.45 MPa
(2.7 … 4.5 bar).
• At a higher engine speed the oil pressure must not be greater
than 0.7 MPa (7 bar).
For engines with identification charactersCDAA,CDAB,CCZA
• When idling, the oil overpressure is 0.12…0.21 MPa (1.2…
2.1 bar).
• At 2000 rpm, the oil overpressure is 0.16 … 0.21 MPa
(1.6 … 2.1 bar).
• At 3700 rpm, the oil overpressure is 0.3 … 0.4 MPa
(3 … 4 bar).
Note
On a new engine, the oil pressure during the first 1000 km can be
between 0.3 … 0.4 MPa (3…4 bar) at 2000 rpm.
Note
If no fault is found:
– Replace oil pump ⇒ page 139 .
If the specification is exceeded:
– Replace oil pump ⇒ page 139 .
Note
Before installing the new oil pump, check the oil channels in the
upper part of the oil sump for contamination.
– Disconnect the plug connections -1-, remove the screw -2- and
remove the valve for oil pressure control - N428- -3-.
Note
Install
Installation is carried out in the reverse order. However, pay at‐
tention to the following:
– Renew O-ring.
– Checking the oil level.
• Tightening torques: ⇒ page 135
2. bracket for auxiliary units with oil filter and engine oil cooler 151
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
19 – Cooling
1 Cooling system
WARNING
Note
1.1 Parts of cooling system on the side next to the body - Summary of compo‐
nents
1 - Radiator
2 - Coolant recirculation pump
- V51-
3 - Coolant pump
4 - Coolant regulator
5 - Engine oil cooler
6 - Cylinder head and cylinder
block
7 - Exhaust gas turbocharger
8 - Expansion reservoir
9 - to auxiliary heating
10 - from the auxiliary heating
11 - Heat exchanger
12 - Coolant connection
1 - Radiator
2 - Coolant recirculation pump
- V51-
3 - Coolant pump
4 - Coolant regulator
5 - Engine oil cooler
6 - Cylinder head and cylinder
block
7 - Exhaust gas turbocharger
8 - Expansion reservoir
9 - to auxiliary heating
10 - from the auxiliary heating
11 - Heat exchanger
12 - Gearbox oil cooler
13 - Coolant connection
14 - Regulators for gearbox oil
coolers
Note
WARNING
– Remove supports for coolant -1- below from the cooler and
allow the coolant to drain.
– Install the charge air hose and secure with shells -1 and 2-.
– Fit the bottom coolant hose -arrow- onto the coolant recircu‐
lation pump - V51- and secure with a spring-type clip.
Vehicles with auxiliary heating
WARNING
1 - Support
2 - Screw
❑ 40 Nm
3 - Coolant hose
4 - Coolant hose
5 - Coolant recirculation pump
- V51-
6 - Support
7 - Screw
❑ 8 Nm
Removing
WARNING
– Press in catches -1- and -3- and pull off connecting hose -4-
from air filter -2-.
2.6 The coolant pump and coolant regulator - List of assembly parts
1 - Screw
❑ 9 Nm
2 - O-rings
❑ replace
3 - Connecting studs
4 - Clip
❑ only in connected ver‐
sion
❑ pay attention to correct
position
5 - Screw
❑ only in an screwed-on
version
❑ 4 Nm
6 - Retaining plate
❑ only in an screwed-on
version
7 - Coolant temperature send‐
er - G62-
❑ replace ⇒ page 166
8 - O-ring
❑ replace
9 - Coolant pump
❑ removing and installing
⇒ page 170
❑ remove the protective
cap on the new coolant
pump
10 - Gasket
❑ replace
11 - Centring bolts
❑ 2 pieces
12 - Toothed belt for coolant pump
❑ removing and installing ⇒ page 167
13 - Toothed belt guard
14 - Screw
❑ 9 Nm
15 - Screw
❑ replace
❑ Left-hand thread
❑ 10 Nm + torque a further 90° (1/4 turn)
– Press in catches -1- and -3- and pull off connecting hose -4-
from air filter -2-.
– Remove throttle valve module - J338- ⇒ page 268 .
Note
To prevent losing too much coolant, insert the new coolant tem‐
perature sender - G62- with O-ring into the connection fitting right
away.
Note
To prevent losing too much coolant, insert the new coolant tem‐
perature sender - G62- with O-ring into the connection fitting right
away.
Install
Installation is carried out in the reverse order. When installing,
observe the following:
Note
Renew O-ring.
Removing
– Remove the small coolant pipe ⇒ page 163 .
– Undo the coolant hose -2- and wiring harness -1-.
– Unscrew the screw -arrow- and remove the mounting bracket.
Caution
Caution
– Unscrew screw -1- on the drive wheel of the coolant pump with
assembly tool - T10360 - in a clockwise direction, hold on tight
to the crankshaft belt pulley with the SW 24 Polydrive socket.
– Remove drive gear -1- and toothed belt -2-.
Install
Installation is carried out in the reverse order. However, pay at‐
tention to the following:
♦ Tightening torques: ⇒ page 164
Note
– Press the screwdriver -1- firmly onto the surface -2- of the
sealing ring -arrow B-.
– Lever out the sealing ring -arrow A-.
WARNING
– Clean the balancing shaft and seat of the sealing ring carefully.
They must be free of oil and grease.
– Fit thrust piece - T10353- to the gasket ring -1- and press in
with screw -2- as far as it goes - do not tilt the gasket ring while
doing so.
– Install toothed belt pulley for coolant pump ⇒ page 167 .
Note
Note
– Press in catches -1- and -3- and pull off connecting hose -4-
from air filter -2-.
Note
Caution
– Undo nuts -2-, unscrew the screw -1- and slide supports for
intake manifold to the right a little.
Note
– Insert the coolant regulator -4- into the housing -5- for coolant
pump and slide them to the front a little -arrow-.
– Carefully fit the support -3-, insert the fitted pin -2- into the
guide -1-.
– Screw on the connection fitting.
– Replace the seal on the oil trap and tighten the screws to 9
Nm in the sequence -1 to 9-.
– Install support for intake manifold ⇒ page 254 .
– Install pump for coolant recirculation - V51- ⇒ page 159 .
– Top up coolant ⇒ page 155 .
– Remove the charge air hose -Pos. 1 and 2- and the charge air
cooler with a clean rag.
WARNING
WARNING
WARNING
Risk of scalding!
♦ Before the cooling system testing device - V.A.G 1274 B-
is separated from the connecting hose or the connecting
piece - V.A.G 1274 B/1- , the existing pressure must ab‐
solutely be released.
♦ For this step, press the pressure relief valve on the cooling
system testing device - V.A.G 1274 B- and hold it pressed
until the pressure gauge indicates the value »0«.
Note
1 - Mounting part
2 - Screw cap
❑ replace if damaged
3 - Earth connection
❑ pay attention to correct
position
4 - Screw
❑ 11 Nm
5 - Cable guide
6 - Screw
❑ replace
❑ 25 Nm
7 - Fuel tank
❑ removing and installing
⇒ page 191
8 - Circlip
9 - Bracket for the exhaust sys‐
tem
10 - Tensioning strap
❑ Check fitting position
11 - Heat shield
12 - Feed line
❑ to fuel rail
❑ pay attention to correct
position
13 - Fuel filter
❑ Fitting position: arrow
points in direction of flow
14 - Vent line
❑ Clipped onto side of fuel tank.
❑ pay attention to correct position
15 - Sealing ring
❑ replace
Note
1 - Feed line
❑ black
❑ check for firm seating
2 - Return-flow line
❑ blue
❑ check for firm seating
3 - Sealing ring
❑ replace
❑ insert dry into the open‐
ing of the fuel tank
❑ only moisten the inner
seal of the flange with
fuel for fitting purposes
4 - Fuel delivery unit
❑ installing and removing
for vehicles up to MY
2008 ⇒ page 199
❑ installing and removing
for vehicles from MY
2009 ⇒ page 202
❑ inspecting fuel pump
⇒ page 206
❑ note the installed posi‐
tion of the fuel tank
⇒ page 184
❑ with sender for fuel
gauge display - G -
❑ Removing and installing
fuel gauge sender - G-
⇒ page 205 .
❑ Clean strainer if dirty
5 - Lock ring
❑ check for firm seating
❑ use wrench - T30101 (3087)- for removing and installing
❑ 110 Nm
6 - Fuel pump control unit - J538-
❑ after replacing, adapt the engine control unit - J623 - to the fuel pump control unit - J538- ⇒ Vehicle
diagnostic tester
❑ check ⇒ Vehicle diagnostic tester
7 - Screw cap
❑ replace if damaged
8 - Fixing screw
9 - Fuel tank lid unit
❑ with rubber bowl
❑ Removing and installing ⇒ Body Work; Rep. gr. 55
10 - Earth connection
❑ check for firm seating
11 - Screw
❑ 11 Nm
12 - Tank ventilation
13 - Connector
❑ for fuel gauge sender -2- - G169-
14 - Fuel gauge sender -2- - G169-
❑ removing and installing ⇒ page 215
15 - Suction spray pump
❑ clipped in place on fuel gauge sender 2 - G169-
❑ removing and installing ⇒ page 215
❑ is a component part of position 14
16 - Tank ventilation
17 - Vent line
18 - Fuel tank
❑ removing and installing ⇒ page 193
19 - Tensioning strap
❑ Check fitting position
20 - Screw
❑ replace
❑ 25 Nm
21 - Screw
❑ 23 Nm
22 - Heat shield
❑ riveted together with hanger of exhaust system
23 - Screw
❑ 3 Nm
24 - Fuel filter
❑ Summary of components ⇒ page 188
25 - Vent line
❑ Clipped onto side of fuel tank.
❑ check for firm seating
Fitting position of the flange of the fuel delivery unit and the fuel
gauge sender -2- - G169-
The marking on the flange must match the label on the fuel tank
-arrows-.
Note
The arrows on the fuel tank are hardly visible due to the floor
panel.
Note
WARNING
Version 1
Push-on coupling with release buttons -arrows- on right and left.
Open
Open
– Press quick coupling in -direction of arrow A-.
– Press release buttons -arrows- and detach quick coupling.
Pay attention to the colour assignment when installing
⇒ page 185 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Version 5
Quick coupling -1- with release buttons -arrows- right and left.
Open
– Press push-on coupling -1- in -arrow direction A- and hold
pressed.
– Press release buttons -2- in -arrow direction B- and remove
quick coupling- 1-.
Pay attention to the colour assignment when installing
⇒ page 185 .
– Check the quick couplings for firm seating by pulling in the
opposite direction!
1 - Fuel filter
❑ with installed pressure
limiting valve for fuel re‐
turn-flow line
Opening pressure:
0.60…0.68 MPa
(6.0 … 6.8 bar)
❑ do not interchange con‐
nections
❑ Fitting position
⇒ page 189
2 - Fuel feed line
❑ black
❑ from fuel tank
❑ press in securing ring in
order to unlock
3 - Fuel return-flow line
❑ blue
❑ to fuel tank
❑ press in securing ring in
order to unlock
4 - Fuel feed line
❑ black
❑ to the engine
❑ press in securing ring in
order to unlock
5 - Screw
❑ 3 Nm
6 - Support
❑ for fuel filter
❑ attached to the fuel tank
♦ Fuel tank
Note
If there are functional problems of the fuel delivery unit suction off
fuel with fuel extraction device e.g. -VAS 5190- .
Work procedure
Note
– Switch off ignition and all electrical loads, and pull out ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip the cover -4- with the fuel pump control unit - J538-
-1-.
Vehicles with auxiliary heating
– Unplug the 2-pin plug of the dosing pump - V54- .
Continued for all vehicles
Note
WARNING
Note
– Switch off ignition and all electrical loads, and pull out ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip the cover -4- with the fuel pump control unit - J538-
-1-.
Note
For vehicles with auxiliary heating, the plug connection for the
dosing pump - V54- must also be disconnected.
– Disconnect vent line -1- (white) and fuel feed line -2- (black)
at the connection point.
Note
♦ For vehicles with auxiliary heating, the fuel line for the dosing
pump - V54- must also be disconnected.
♦ Press in the securing ring in order to unlock the line.
– Release fixing screws -2- and -4- and remove the tensioning
strap.
– Support fuel tank using the engine/gearbox jack - V.A.G 1383
A- .
– Release fixing screws -1- and -3-.
– Slightly lower the fuel tank.
Note
Install
– Check if the earth lead shows traces of oxidation on both con‐
nections, remove if necessary.
– Clip on cover -4- with fuel pump control unit - J538- -1-.
The arrow -2- on the cover points in direction of travel.
Note
– Switch off all electrical components and take out the ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip the cover -4- with the fuel pump control unit - J538-
-1-.
Vehicles with auxiliary heating
– Unplug the 2-pin plug of the dosing pump - V54- .
– Remove the rubber grommet from the cover of the fuel delivery
unit and pull out the wiring.
Continued for all vehicles
– Remove the cover of the fuel gauge sender -2- - G169- (in the
figure on the right) and unplug the plug -right arrows-.
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew the cap from the fuel filler neck.
– Close the opening of the fuel filler neck with a clean foam
piece, so that no dirt can penetrate.
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Disconnect vent line -1- (white) and fuel feed line -2- (black)
at the connection point.
Note
– Clip on cover -4- with fuel pump control unit - J538- -1-.
The arrow -2- on the cover points in direction of travel.
Note
– Switch off ignition and all electrical loads, and pull out ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip the cover -4- with the fuel pump control unit - J538-
-1-.
Note
For vehicles with auxiliary heating, the plug connection for the
dosing pump - V54- must also be disconnected.
– Unplug the 5-pin plug, the black feed line -1- and the blue re‐
turn-flow line -2-.
Note
Note
♦ Remove fuel delivery unit from the fuel tank so that the electric
lines and fuel hoses are not damaged and the float arm of the
sender for fuel gauge display - G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
Installation is carried out in reverse order. Pay attention to the
following:
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.
– Insert the fuel delivery unit into the fuel tank in such a way that
the float arm of the sender for the fuel gauge display - G- is
not bent.
– Press the closing flange downwards, install the lock ring and
connect the fuel lines.
Note
Octavia II
Superb II
Note
– Clip on cover -4- with fuel pump control unit - J538- -1-.
The arrow -2- on the cover points in direction of travel.
Note
Note
For vehicles with auxiliary heating, the plug connection for the
dosing pump - V54- must also be disconnected.
– Disconnect the plug as well as the black feed line -1- and the
blue return-flow line -2- from the flange.
Note
– Separate through the opening of the fuel tank the fuel line
-1- to the suction jet pump, to do so press the release button.
– Unhook the fuel delivery line -2- at the fuel delivery unit, to do
so pull the fixing clamp upwards -arrow-.
Note
♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
- G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
The installation of the fuel delivery unit occurs in the reverse or‐
der. Pay attention to the following:
– Insert the fuel delivery unit into the fuel tank with the closing
flange placed to the side. Thus, do not bend the float arm of
the fuel gauge sender unit - G- .
– Install the fuel delivery unit and the fuel line.
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.
– Slide the spring -2- into the guide bore -arrow- and fit the cable
-1- of the closing flange on the cable -3- of the fuel delivery
unit.
– Press the closing flange down and bring it into the installation
position.
Further information:
♦ Observe the fitting location of the fuel delivery unit. The peg
-2- at the closing flange must be located between the pegs
-1- and -3-. The -thick arrow- points in the direction of travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
line and the return-flow line are still clipped in place on the fuel
tank.
Note
– Switch off ignition and all electrical loads, and pull out ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip the cover -4- with the fuel pump control unit - J538-
-1-.
Vehicles with auxiliary heating
– Unplug the 2-pin plug of the dosing pump - V54- .
Continued for all vehicles
– Disconnect the plug as well as the black feed line -1- and the
blue return-flow line -2- from the flange.
Note
– Slightly raise the closing flange and check if the spring -2- is
still fastened on the flange -1-.
If the spring -2- is loose on the guide pipe -3-, hold it with your
fingers while removing the closing flange.
– Pull out closing flange and gasket ring of the fuel delivery unit
from the opening of the fuel tank and place to the side with the
connected lines.
– Remove the suction jet pump fuel gauge sender -2- - G169-
⇒ page 215 .
– Separate through the opening of the fuel tank the fuel line
-1- to the suction jet pump, to do so press the release button.
– Separate the fuel delivery line -2- from the fuel delivery unit.
Note
♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
- G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
Installation is carried out in reverse order. However, pay attention
to the following:
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.
– Insert the fuel delivery unit into the fuel tank with the closing
flange placed to the side. Thus, do not bend the float arm of
the fuel gauge sender unit - G- .
– Install the fuel delivery unit and the fuel line.
• The spring -2- must be fastened to the retaining lugs -1- of the
closing flange.
– First of all guide the guide pipe -3- into the guide bore -4-.
– Then lower the closing flange in such a way that the guide pipe
-6- locks into the guide bore -5-.
Note
Pay attention that the electrical cables -1- and the fuel feed line
-3- are routed according to the illustration and the float arm -2- is
not blocked.
– Press the closing flange down and bring it into the installation
position.
Further information:
♦ Fitting location of the fuel delivery unit: The peg -2- at the clos‐
ing flange must be located between the pegs -1- and -3-. The
-thick arrow- points in the direction of travel.
Octavia II
♦ After installing the fuel delivery unit, check whether the feed
line and the return-flow line are still clipped in place on the fuel
tank.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
line and the return-flow line are still clipped in place on the fuel
tank.
Note
There are two types of senders for the fuel gauge display - G-
installed in the vehicles.
Note
Note
Note
– After pressure has built up, cut-off tap -B- of pressure tester
immediately. Lever is then at right angle to direction of flow.
If the pressure does not drop now:
Note
– After the pressure has built up, close the shut-off cock -A-.
– Observe pressure drop at pressure gauge.
• The pressure must not drop below 0.3 MPa (3 bar) after 10
minutes.
If the pressure drops:
– Non-return valve in the fuel pump faulty, replace fuel delivery
unit ⇒ page 202 .
If the pressure does not drop:
– Pressure limiting valve in the fuel filter defective, replace the
fuel filter.
Note
– Switch off ignition and all electrical loads, and pull out ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Unclip the cover -4- with the fuel pump control unit - J538-
-1-.
Note
This step is only intended to ensure that the fuel delivery unit runs
when the engine is switched off.
WARNING
– The fuel flow rate of the fuel pump is dependent on the battery
voltage. For this reason, additionally connect the multimeter -
V.A.G 1715- to the outgoing circuits -1 and 5- of the adapter
for measuring method/DSO (5-pin) - VAS 5565- .
– Operate remote control for 30 seconds, whilst measuring volt‐
age at fuel pump.
Note
If the fault in the fuel supply system is intermittent then tests can
be undertaken during a test drive but then two people are required
for this.
Note
Removing
– Switch off all electrical components and take out the ignition
key.
– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
– Remove fuel delivery unit:
♦ For vehicles up to MY 2008 ⇒ page 199
♦ For vehicles from MY 2009 ⇒ page 202
– Remove the left cover in direction of travel from the fuel gauge
sender -2- - G169- .
Install
Caution
When installing do not bend the float arm of the fuel gauge
sender -2- - G169 - .
– Insert the fuel gauge sender 2 - G169 - into the fuel tank.
– Position the suction jet pump in the interior of the fuel tank onto
the sender. The catches must click audibly.
– Insert new dry gasket ring for the flange into the opening of the
fuel tank and only now moisten the inside (position of the
flange) with fuel.
– Pay attention to the fitting location of the fuel gauge sender -2-
- G169- ⇒ page 184 .
– Check correct seating of the gasket ring.
– Tighten lock ring with wrench for union nut - T30101- .
Tightening torque: 110 Nm
– Mount the plug connection.
– Install cover.
– Install sill panel ⇒ Body Work; Rep. gr. 72 .
2 Accelerator pedal
1 - Connector
❑ Black, 6-pin.
❑ disconnect and fit on
⇒ page 220
2 - Accelerator pedal module
❑ with accelerator pedal
position sender - G79-
and accelerator pedal
position sender 2 -
G185-
❑ for vehicles with auto‐
matic gearbox with kick-
down switch
❑ not adjustable
❑ -A- openings for the re‐
lease tool
❑ removing and installing
⇒ page 218
❑ After replacing in vehi‐
cles with automatic
gearbox, adjust the en‐
gine and gearbox con‐
trol unit ⇒ Vehicle diag‐
nostic tester
3 - 10 Nm
4 - Cap
Removing
– Remove steering column cover -arrows-.
– Lever out the cap ( ⇒ page 218 Pos. 4) with a screwdriver.
– Release fixing screw ( ⇒ page 218 Pos. 3).
– Fit the connector -2- onto the accelerator pedal module -5-
⇒ page 220 .
– Push accelerator pedal module onto the retaining bolts -6-.
– Insert the centering pin -7- into the hole in the underbody.
– Fasten accelerator pedal module with screw -3- (10 Nm) and
fit on cap -4-.
– Re-install steering column cover.
– If the accelerator pedal module was replaced on vehicles with
automatic gearbox, the engine control unit must be adapted
⇒ Vehicle diagnostic tester.
Note
The plugs for the accelerator pedal module which are inserted,
must be disconnected and fit on in a different manner.
Note
12 - Screw
❑ 12 Nm
13 - Activated charcoal filter solenoid valve 1 - N80-
❑ version assembled up to 11.2010
❑ with air bleed valve
❑ Valve closed with ignition switched off.
❑ valve is actuated (pulsed) by engine control unit when engine is warm
❑ attached to intake manifold ⇒ page 254
❑ with double non-return valve, one building unit
❑ the intake manifold must be removed for removing and installing
14 - Connecting hose
15 - Activated charcoal filter solenoid valve 1 - N80-
❑ version assembled from 11.2010
❑ with air bleed valve
❑ Valve closed with ignition switched off.
❑ valve is actuated (pulsed) by engine control unit when engine is warm
❑ attached to intake manifold ⇒ page 254
❑ the intake manifold must be removed for removing and installing
– Connect the hand vacuum pump - V.A.S 6213- with the adapt‐
er - VAS 6550/3-1 - to the vent pipe to the activated charcoal
filter.
– Put the sliding ring -1- of the hand vacuum pump - V.A.S 6213-
in position-A- for “vacuum”
– Operate hand vacuum pump - V.A.S 6213- several times.
• Vacuum must not build up.
If vacuum builds up:
– Check the air admission fitting on the activated charcoal filter
for dirt and clean as required.
If vacuum does not build up:
– Shut off air admission fitting -arrow- and once again operate
the vacuum pump several times. Vacuum must build up.
If vacuum does not build up:
– Replace activated charcoal filter.
21 – Turbocharging/supercharging
1 Exhaust gas turbocharger
Note
Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 7 .
Part 2
1 - Sealing ring
❑ replace
2 - Screw
❑ 33 Nm
3 - Oil feed line
4 - Exhaust gas turbocharger
❑ can only be replaced
with exhaust manifold
and pressure box
❑ removing and installing
⇒ page 228
5 - Screw
❑ 9 Nm
6 - Screw
❑ 9 Nm
7 - Sealing ring
❑ replace
8 - Screw
❑ tighten with Bit XZN 12 -
T10099-
❑ 38 Nm
9 - Screw
❑ 9 Nm
10 - Screw
❑ the turbocharger must
be removed for remov‐
ing and installing
❑ 38 Nm
11 - Sealing ring
❑ replace
12 - Coolant feed line
❑ the turbocharger must be removed for removing and installing
13 - O-ring
❑ replace
14 - Screw
❑ 9 Nm
15 - Gasket
❑ replace
16 - Oil return-flow line
17 - Screw
❑ 9 Nm
18 - Gasket
❑ replace
Part 3
1 - Gasket
❑ replace
2 - Nut
❑ replace
❑ removing and installing
⇒ page 228
❑ Coat stud bolts of the
cylinder head with hot
bolt paste - G 052 112
A3-
3 - Screw
❑ the turbocharger must
be removed for remov‐
ing and installing
❑ 38 Nm
4 - Sealing ring
❑ replace
5 - Coolant return-flow line
❑ the turbocharger must
be removed for remov‐
ing and installing
6 - Screw
❑ 9 Nm
7 - Exhaust gas turbocharger
❑ can only be replaced
with exhaust manifold
and pressure box
❑ removing and installing
⇒ page 228
8 - Support
9 - Screw
❑ Wet screw with hot bolt paste - G 052 112 A3-
❑ 30 Nm
10 - Screw
❑ Wet screw with hot bolt paste - G 052 112 A3-
❑ 30 Nm
11 - Screw
❑ replace
❑ do not remove for removing the turbocharger
❑ Coat stud bolts of the cylinder head with hot bolt paste - G 052 112 A3-
❑ 30 Nm
12 - Terminal strip
Part 4
Note
Only engine identification characters BZB, CDAA and CDAB have an adjustable pressure box built in.
Caution
Removing
– Drain coolant ⇒ page 155 .
– Remove the front right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
Vehicles with front-wheel-drive
– Unbolt heat shield for right drive shaft -arrows-.
Vehicles with four-wheel drive
– Remove the hollow screw -2- and place the coolant line to one
side.
Vehicles with front-wheel-drive
– Unscrew screws -1- at the oil return line.
Vehicles with four-wheel drive
– Unscrew the screws on the oil return line at the cylinder block.
Continued for all vehicles
– Unscrew screw -3- at the oil feed line.
Note
– Press the release buttons and remove pipe -2- for crankcase
ventilation.
– Release screw -arrow-.
– Loosen hose clamp -1- and remove the intake manifold.
Note
– Remove the connector from the ignition coils and place the
wiring harness to one side.
Note
Remove screw -2- from the heat shield using an adapter with 6
mm hex -A-. The minimum shape of the hexagon must be 5 cm
-B-. The adapter which narrows to 6 mm at the tip, is too thick.
Work procedure
– Remove engine cover ⇒ page 9 .
– Switch the engine on. With a mirror, observe the operating rod
-A- of the pressure box on the turbocharger.
– Now bring the engine with a second mechanic up to high rev‐
olutions by spontaneously pressing on the accelerator pedal.
• The linkage -A- should now move.
If the linkage does not move:
– Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
in position -B- for “pressure”.
Caution
The pressure must not be greater than 0.075 MPa (750 mbar).
The pressure box can be damaged if the pressure is exceeded.
– Press the hand vacuum pump - V.A.S 6213- several times and
observe the linkage using the mirror.
Note
Note
♦ This workflow is only used to set the pressure box. The values
may vary when inspecting pressure boxes which have already
been set.
♦ The pressure box must only be set when the linkage was un‐
done.
♦ This setting is made when the turbocharger is removed.
– Remove the lock washer -1- from the turbocharger via the
linkage of the pressure box.
– Pre-set the bypass valve -1- via the linkage of the pressure
box -arrow- so that the bypass valve can still just about be
rotated from its position with the hand.
– Tighten locknuts until hand-tight.
– Put the sliding ring -1- of the hand vacuum pump - VAS 6213-
in position -B- for “pressure”.
– Switch on the turbocharger tester - V.A.G 1397A- and put the
sliding switch into position II.
Note
Note
– Press the hand vacuum pump - VAS 6213- until the turbo‐
charger tester - V.A.G 1397 A- indicates 0.046 MPa ± 0.0005
MPa (460 mbar ± 5 mbar).
– Read the value on the dial gauge - VAS 6341/1- (value 1) and
note it down.
– Press the hand vacuum pump - VAS 6213- until the turbo‐
charger tester - V.A.G 1397 A- indicates 0.065 MPa 0.070
MPa (650 mbar to 700 mbar).
– Reduce pressure via pressure control valve - VAS 6342- to
0.046 MPa 0,0005 MPa (460 mbar ± 5 mbar).
– Read the value on the dial gauge - VAS 6341/1- (value 2) and
note it down.
– Add values 1 and 2 together and divide by 2.
• The result (mean) must be 5 ± 0.25 mm.
If the result (mean) is not 5 ± 0.25 mm.
– Correct the setting, tighten the locknut until hand-tight, and
repeat the measurement.
If the result (mean) is 5 ± 0.25 mm.
– Secure the lock washer -1- to the turbocharger via the linkage
of the pressure box.
1 - Screw
❑ 5 Nm
2 - Bearings
❑ for charge air cooler
3 - Charge air cooler
❑ with top and bottom seal
inserted
❑ removing and installing
⇒ page 241
4 - Charge air pipe
5 - Screw
❑ 10 Nm
6 - from exhaust turbocharger
7 - Charge air hose
8 - to throttle valve control unit
- J338-
9 - Charge air hose
10 - Screw
❑ 10 Nm
11 - Screw
❑ 5 Nm
12 - Charge pressure sender -
G31-
13 - Charge air pipe
14 - Charge air hose
1 - Screw
❑ 5 Nm
2 - Bearings
❑ for charge air cooler
3 - Charge air cooler
❑ with top and bottom seal
inserted
❑ removing and installing
⇒ page 241
4 - Charge air pipe
5 - Screw
❑ 10 Nm
6 - from exhaust turbocharger
7 - Charge air hose
8 - to throttle valve control unit
- J338-
9 - Charge air hose
10 - Screw
❑ 10 Nm
11 - Screw
❑ 5 Nm
12 - Charge pressure sender -
G31-
13 - Charge air pipe
14 - Charge air hose
WARNING
Caution
– With the aid of 2nd mechanic, press off the charge air cooler
from the lock carrier so that the screw -1- for attaching the
pipes of the air conditioning system is accessible.
– Remove screw -1-.
– Attach condensor to lock carrier.
– Carefully remove charge air cooler downwards.
Install
Installation is carried out in the reverse order. When installing,
observe the following:
Note
Replace O-rings.
Caution
The screw clamps -A- on the charge air hoses must be tight‐
ened to 6 Nm. A too low, but also a too high tightening torque,
may result in the hose slipping off the charge air pipe during
driving.
Note
Caution
Removing
– Plug the adapter - V.A.G 1687/5- onto the charge air hose
-A- and turn by approx. 90° -B-.
Prepare tester for charge air system - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
Note
If there is water in the inspection glass, drain water via the drain
plug -6-.
Caution
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary regulate the pressure to 0.05 MPa (0.5 bar).
– Listen to, touch or use commercially available leak search
spray or the ultrasonic measuring device - V.A.G 1842- to
check the charge-air system for leak points.
Note
♦ A small amount of air escapes via the valves into the engine.
For this reason no pressure test is possible.
♦ Use of ultrasonic measuring device - V.A.G 1842- ⇒ operating
instructions .
♦ Before removing the adapter, depressurize the test circuit by
detaching the coupling from the adapter - V.A.G 1687/5- .
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.
Contact assignment
1- for hall sender - G40-
2- for knock sensor 1 - G61-
3- 8-pin plug connection for injection valves
Note
1 - Bolts
❑ 5 Nm
2 - Intake air temperature
sender - G42-
3 - Activated charcoal filter sol‐
enoid valve 1 - N80-
❑ with double non-return
valve, one building unit
❑ the intake manifold must
be removed for remov‐
ing and installing
4 - Intake manifold
❑ removing and installing
⇒ page 257
5 - Positioning element for
valve for intake manifold flap
❑ check ⇒ page 281
6 - Screws for high pressure
pump
❑ replace
❑ M6 thread for 1.8 l en‐
gines: 8 Nm + torque a
further 90° (1/4 turn)
❑ M8 thread for 2.0 l en‐
gines: 20 Nm
7 - Connection fitting for fuel
feed line
8 - Control valve for fuel pres‐
sure - N276-
9 - High pressure pump
❑ with fuel pressure regu‐
lating valve - N276 -
❑ removing and installing ⇒ page 274
10 - Roller tappet
❑ can remain inserted into the vacuum pump after removal of the high pressure pump, removable
11 - Connection fitting for high-pressure fuel line
❑ replace
❑ 22 Nm
12 - High-pressure fuel line
❑ do not install under tension
❑ 18 Nm
13 - Valve for intake manifold flap - N316-
14 - Injectors
❑ The intermediate ring -1- and mount -2- do not belong to the scope of supply of the new injection valve
⇒ page 257
1 - Injector
❑ The intermediate ring
-1- and mount -2- do not
belong to the scope of
supply of the new injec‐
tion valve ⇒ page 257
❑ When replacing the in‐
jection valve, the inter‐
mediate ring -1- and
mount -2- must be or‐
dered later from the in‐
jection valve repair kit ⇒
ETKA - Electronic Cata‐
logue of Original Parts
❑ Replace the O-Ring -6-
and combustion cham‐
ber seal -3- (Teflon seal)
⇒ page 257
❑ removing and installing
⇒ page 276
2 - Support ring
3 - Fuel distributor
❑ removing and installing
⇒ page 257
4 - High pressure pump
❑ with fuel pressure regu‐
lating valve - N276 -
❑ High-pressure fuel line
at high pressure pump:
17 Nm
❑ Before removing the
high-pressure pump,
the fuel pressure must
be reduced to residual
pressure. ⇒ page 5
❑ Do not install high-pres‐
sure fuel line under tension
❑ when installing the high pressure pump, ensure that no dirt can get into the fuel system.
❑ removing and installing ⇒ page 274
5 - Roller tappet
❑ can remain inserted into the vacuum pump after removal of the high pressure pump, removable
6 - Control valve for fuel pressure - N276-
7 - Screws for high pressure pump
❑ replace
❑ M6 thread for 1.8 l engines: 8 Nm + torque a further 90° (1/4 turn)
❑ M8 thread for 2.0 l engines: 20 Nm
8 - Connection fitting for fuel feed line
❑ replace
❑ 25 Nm
9 - Union nut in the fuel feed line
❑ 18 Nm
10 - Divider plate
11 - Gasket
❑ replace
12 - Intake manifold
❑ removing and installing ⇒ page 257
13 - Positioning element for valve for intake manifold flap
14 - Throttle valve control unit - J338-
❑ with throttle valve drive for electronic power control - G186 - , angle sensor 1 for throttle valve drive for
electronic power control - G187- and angle sensor 2 for throttle valve drive for electronic power control
- G188-
❑ after replacement, erase adapted values and adjust engine control unit to the throttle flap control unit
⇒ Vehicle diagnostic tester
❑ removing and installing ⇒ page 268
❑ Clean ⇒ page 269
15 - Screws for the intake manifold
❑ firstly, pre-tighten all screws to 3 Nm, and then pre-tighten to 9 Nm
16 - Potentiometer for intake manifold flap - G336-
❑ after replacing, adjust the engine control unit to the potentiometer for the intake manifold flap ⇒ Vehicle
diagnostic tester
17 - Fuel pressure sender - G247-
❑ Moisten thread with clean engine oil
❑ check ⇒ page 263
❑ removing and installing ⇒ page 268
❑ 27 Nm
Note
Removing
WARNING
– Disconnect the vacuum line -1- from the isolating point -2- and
remove the hose for crankcase ventilation -3-.
– Unscrew the screws -arrows- on the fuel feed line, and place
the cable to one side.
– Unscrew the union nut on the fuel line -bottom arrow- at the
high pressure pump.
– Remove vacuum cable -arrow- from the valve for intake mani‐
fold flap - N316- .
– Unscrew the nuts -1-, unscrew the screw -2- and remove the
intake manifold support.
– Unscrew the oil filter with the oil filter removal tool - 3417- .
– Cover the oil filter holder.
Note
Note
Make sure the injection valves are in the correct fitting position;
watch out for the cable holder (underneath the intake manifold)
when fitting the intake manifold.
– Clip in all latches when latching the cable holder to the intake
manifold.
Tightening torques:
♦ Intake manifold - Summary of components: ⇒ page 254
♦ Fuel distributor - summary of components: ⇒ page 256
Note
WARNING
Work procedure
– Remove fuel pressure sender - G247- -1- ⇒ page 266
– Release the screw plug -2- and screw the fuel pressure sender
- G247- into the tester - VAS 6394/1- .
Tightening torque 22 Nm.
– Screw pressure line -1- of the pressure gauge - VAS 6394/1-
onto the adapter - VAS 6294/2- until hand-tight.
– Switch on the tester - VAS 6394/1- , for this step, briefly press
the button -A- once.
Note
Self-diagnosis ►
01 - Engine Electronics ►
Removing
Note
– Switch off ignition and all electrical loads, and pull out ignition
key.
WARNING
Note
Hold the connections at the high pressure pump and at the bottom
part of intake manifold/fuel distributor when tightening the union
nuts with a wrench.
– Unscrew union nuts -arrows- and screw -1- and remove high
pressure line.
Note
♦ The fuel line bracket must not become bent in any circum‐
stances.
♦ If the bracket becomes bent the fuel line must be replaced, as
must the bracket.
– Slacken clamps -1- and -2- and remove the charge air hose.
– Disconnect the plug -1- from the throttle valve control unit -
J338 - .
– Release screws -arrows- and remove throttle valve control unit
- J338- .
Install
Installation is carried out in the reverse order. However, pay at‐
tention to the following:
♦ Tightening torques: ⇒ page 254
– Clean the original throttle valve control unit - J338- before re-
installation ⇒ page 266 .
– Clean the sealing flange for the gasket ring.
– Replace gasket ring.
– If a new throttle flap control unit - J338- was installed, adjust
the engine control unit to the throttle flap control unit - J338-
⇒ Vehicle diagnostic tester.
Note
Work procedure
– Remove throttle valve module ⇒ page 268 .
– Open the throttle valve manually and block the throttle valve
in the opened position with a suitable object -arrow-.
WARNING
3 Air filter
Note
4 - Bolts
❑ Captive screws for up‐
per part of the air filter
❑ 2 Nm
5 - Bolts
❑ Captive screws for up‐
per part of the air filter
❑ 2 Nm
6 - Air filter top part
7 - Filter element
8 - Bolts
❑ Captive screws for low‐
er part of the air filter
❑ 8 Nm
9 - Snow strainer
❑ Not installed in all vehicles
10 - Air filter bottom part
❑ remove salt residues, dirt and leaves from the lower part of the air filter
11 - Connection for the water drain hose
❑ clean the connection
12 - Water drain hose
❑ clean the water drain hose
13 - Overrun valve
14 - Connecting hose
❑ to the lock carrier
Note
– Release screws -arrows- for inlet connection -1- and take con‐
necting hose-2- out of the guide.
– Remove inlet connection -1-.
– Remove connector -2- from the airflow meter - G70- and intake
air temperature sender 2 - G299- .
– Open and remove spring-type clip -1-.
– Unscrew screw -3-.
– Loosen the air filter housing at the two mandrels and remove
towards the top and underneath the top coolant hose.
Install
– Installation is carried out in the reverse order.
WARNING
Note
Note the different versions of the connection fitting on the high-pressure fuel line.
1 - O-ring
❑ replace
2 - Roller tappet
❑ can remain inserted into
the vacuum pump after
removal of the high
pressure pump, remov‐
able
3 - Connecting fitting on the
high-pressure fuel line (with fe‐
male thread)
❑ replace
❑ when undoing the union
nut -Pos. 5- hold the
connection fitting in
place
❑ 40 Nm
4 - Connecting fitting on the
high-pressure fuel line (with
male thread)
❑ replace
❑ when undoing the union
nut -Pos. 5- hold the
connection fitting in
place
❑ 25 Nm
5 - Union nut for high-pressure
fuel line
❑ Do not install high-pres‐
sure fuel line under ten‐
sion
❑ 18 Nm
6 - Fuel feed line from fuel tank
7 - Screws for high pressure pump
❑ replace
❑ M6 thread for 1.8 l engines: 8 Nm + torque a further 90° (1/4 turn)
❑ M8 thread for 2.0 l engines: 20 Nm
WARNING
Note
♦ Installing and removing the high pressure pump only when the
engine is cold.
♦ When installing the high pressure pump, ensure that no dirt
can get into the fuel system.
♦ Collect the fuel which flows out with a cleaning cloth.
♦ O-ring and connection fitting must always be replaced.
♦ Always screw in high-pressure fuel lines tension-free.
Note
Note
5 Injectors
Note
The puller - T10133/2 - tool has been modified and is now called
extractor - T10133/2A - . If you do not have the new tool, you can
carry out this modification yourself.
Note
Install
Caution
Note
5. Injectors 277
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
Note
♦ The intermediate ring -1- and mount -2- do not belong to the
scope of supply of the new injection valve
♦ When replacing the injection valve, the intermediate ring -1-
and mount -2- must be ordered later from the injection valve
repair kit ⇒ ETKA - Electronic Catalogue of Original Parts .
Caution
– Fit a new gasket ring -1- onto the assembly cone - T10133/5- .
Slightly push the gasket ring with the assembly sleeve -
T10133/6- (knurling points to the gasket ring -1-) as far as
possible onto the assembly cone - T10133/5 - .
5. Injectors 279
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
1.8/112; 118 kW TSI; 2.0/147 kW TSI engine - Edition 04.2014
6 Testing components
Note
Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system as well as rules
for cleanliness ⇒ page 3 .
Only carry out the check when there is a torque deficiency. This
means there is a lack of elasticity or pulling power.
Test condition
• The valve for intake manifold flap - N316- was inspected with
the ⇒ Vehicle diagnostic tester.
Test sequence
If the valve for intake manifold flap - N316- OK, carry out the fol‐
lowing tests:
– Remove engine cover ⇒ page 9 .
– Start engine and run in idle.
– Have a 2nd person, increase the engine speed suddenly (gas
shock). Note the vacuum positioning element for intake mani‐
fold change-over.
• The positioning element must tighten -arrow-.
If the change-over does not work as indicated:
– Check the vacuum system for tightness.
– Check the change-over mechanism for ease of movement. To
this end activate the linkage by hand.
– Check the vacuum lines for the correct connection.
– Check the vacuum hoses for porosity.
– Remove the vacuum hose -1- to the positioning element for
valve for intake manifold flap at the valve for intake manifold
flap - N316- -2-.
– Put the change-over ring -1- of the hand vacuum pump - VAS
6213- in position-A- for “vacuum”
– Connect the hand vacuum pump - VAS 6213 - on the posi‐
tioning element for valves for intake manifold flap.
– Put the change-over ring -1- of the hand vacuum pump - VAS
6213- in position-A- for “vacuum”
Note
♦ In order to unplug the plugs from the control unit, the control
unit must always be removed.
♦ If the engine control unit must be replaced, connect the ⇒ Ve‐
hicle diagnostic tester and in “perform the replace engine
control unit” targeted fault finding.
– Cut with body saw -1- a slot for the cross-head screwdriver in
the heads of the pull-off screws -2-.
Note
♦ It must be sawed twice with the body saw, so that the slot is
wide enough, in order to unscrew the screws with a suitable
screwdriver.
♦ A locking agent is applied to the pull-off screws.
Note
For vehicles with protective cover, the metal swarfs must be suc‐
tioned out of the plenum chamber before installing the engine
control unit.
Note
♦ In order to unplug the plugs from the control unit, the control
unit must always be removed.
♦ If the engine control unit must be replaced, connect the ⇒ Ve‐
hicle diagnostic tester and in “perform the replace engine
control unit” targeted fault finding.
– Open retaining clip -arrow- and remove the engine control unit
- J623- .
Vehicles with protective cover
– Cut with body saw a slot for the cross-head screwdriver in the
heads of the pull-off screws -3- and -4-.
Note
♦ It must be sawed twice with the body saw, so that the slot is
wide enough, in order to be able to unscrew the screws with
a suitable screwdriver.
♦ A locking agent is applied to the pull-off screws.
– Unscrew the screws and remove the protective cover for the
plug connections -2- and -5-.
Continued for all vehicles
– Unlock both plugs at engine control unit and unplug.
Install
Note
For vehicles with protective cover, the metal swarfs must be suc‐
tioned out of the plenum chamber before installing the engine
control unit.
– Push engine control unit into the bracket and lock with retain‐
ing clip -arrow-.
– Install bulkhead plenum chamber and plenum chamber cover
⇒ Body Work; Rep. gr. 66 .
26 – Exhaust system
1 Removing and installing parts of the
exhaust system
1 - Gasket
❑ replace
2 - Nut
❑ replace
❑ Coat stud bolts of ex‐
haust manifold with hot
bolt paste - G 052 112
A3- before installing.
❑ 40 Nm
3 - Lambda probe - G39-
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ if a re-used lambda
probe is installed, only
coat the thread with hot
bolt paste - G 052 112
A3- ; the hot bolt paste -
G 052 112 A3- must not
get into the slots of the
probe body
❑ 55 Nm
4 - Exhaust pipe with catalytic
converter
❑ protect against shocks
and blows
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Secure decoupling ele‐
ment with transport se‐
curity - T10403-
❑ removing and installing
⇒ page 296
❑ Align exhaust system
free of stress ⇒ page 299
5 - Clamp
❑ align exhaust system free of stress before tightening ⇒ page 299
❑ Fitting position ⇒ page 299
❑ Tighten bolted connections evenly
6 - Screw
❑ 23 Nm
7 - Nuts
❑ 20 Nm
8 - Front tunnel bridge
9 - Retaining strap
❑ replace if damaged
10 - Rear part of the exhaust system (Octavia II)
❑ for first equipment building unit with middle part of exhaust gas system, replace individually when carrying
out repairs
❑ replace ⇒ page 298
❑ Align exhaust system free of stress ⇒ page 299
11 - Clamping sleeve
❑ align exhaust system free of stress before fitting on ⇒ page 299
❑ Fitting position ⇒ page 299
❑ Tighten bolted connections evenly
12 - Retaining strap
❑ replace if damaged
13 - Rear part of the exhaust system (Superb II)
❑ Can only be replaced completely for repair.
❑ Align exhaust system free of stress ⇒ page 299
14 - Rear tunnel bridge
15 - Middle part of the exhaust system (Octavia II)
❑ for first equipment building unit with rear part of exhaust gas system, replace individually when carrying
out repairs
❑ replace ⇒ page 298
❑ Align exhaust system free of stress ⇒ page 299
16 - Bracket for the exhaust system
❑ firmly riveted with the protection plate of the fuel tank
17 - Hanger
❑ replace if damaged
18 - Hanger
❑ replace if damaged
1 - Gasket
❑ replace
2 - Nut
❑ replace
❑ Coat stud bolts of ex‐
haust manifold with hot
bolt paste - G 052 112
A3- before installing.
❑ 40 Nm
3 - Lambda probe upstream of
catalytic converter - G39-
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ if a re-used lambda
probe is installed, only
coat the thread with hot
bolt paste - G 052 112
A3- ; the hot bolt paste -
G 052 112 A3- must not
get into the slots of the
probe body
❑ 55 Nm
4 - Exhaust pipe with catalytic
converter
❑ Pay attention to the part
number
❑ protect against shocks
and blows
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Secure decoupling ele‐
ment with transport se‐
curity - T10403-
❑ removing and installing ⇒ page 296
❑ Align exhaust system free of stress ⇒ page 299
5 - lambda probe downstream of catalytic converter - G130-
❑ the thread of new lambda probes must be coated with assembly paste
❑ if a re-used lambda probe is installed, only coat the thread with hot bolt paste - G 052 112 A3- ; the hot
bolt paste - G 052 112 A3- must not get into the slots of the probe body
❑ 55 Nm
6 - Clamp
❑ align exhaust system free of stress before fitting on ⇒ page 299
❑ Tighten bolted connections evenly
7 - Screw
❑ 23 Nm
8 - Nuts
❑ 20 Nm
9 - Front tunnel bridge
10 - Retaining strap
❑ replace if damaged
1 - Gasket
❑ replace
2 - Nut
❑ replace
❑ Coat stud bolts of ex‐
haust manifold with hot
bolt paste - G 052 112
A3- before installing.
❑ 40 Nm
3 - Lambda probe upstream of
catalytic converter - G39-
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ if a re-used lambda
probe is installed, only
coat the thread with hot
bolt paste - G 052 112
A3- ; the hot bolt paste -
G 052 112 A3- must not
get into the slots of the
probe body
❑ 55 Nm
4 - Hanger
❑ replace if damaged
5 - Screw
❑ 23 Nm
6 - Exhaust pipe with catalytic
converter
❑ Octavia II up to 08.2011
❑ Superb II from 09.2010
❑ protect against shocks
and blows
❑ do not twist decoupling element more than 10° - risk of damage
❑ Secure decoupling element with transport security - T10403-
❑ removing and installing ⇒ page 296
❑ Align exhaust system free of stress ⇒ page 299
7 - lambda probe downstream of catalytic converter - G130-
❑ the thread of new lambda probes must be coated with assembly paste
❑ if a re-used lambda probe is installed, only coat the thread with hot bolt paste - G 052 112 A3- ; the hot
bolt paste - G 052 112 A3- must not get into the slots of the probe body
❑ 55 Nm
8 - Exhaust pipe with catalytic converter
❑ Octavia II up to 08.2011
❑ Superb II up to 09.2010
❑ protect against shocks and blows
❑ do not twist decoupling element more than 10° - risk of damage
❑ Secure decoupling element with transport security - T10403-
❑ removing and installing ⇒ page 296
❑ Align exhaust system free of stress ⇒ page 299
9 - Middle and rear part of the exhaust system
❑ Can only be replaced completely for repair.
❑ Align exhaust system free of stress ⇒ page 299
10 - Hanger
❑ replace if damaged
11 - Tunnel bridge
12 - Nuts
❑ 20 Nm
13 - Retaining strap
❑ replace if damaged
14 - Hanger
15 - Clamping sleeve
❑ align exhaust system free of stress before fitting on ⇒ page 299
❑ Tighten bolted connections evenly
1 - Gasket
❑ replace
2 - Bolts
❑ replace
❑ Coat stud bolts of ex‐
haust manifold with hot
bolt paste - G 052 112
A3- before installing.
❑ 40 Nm
3 - Lambda probe upstream of
catalytic converter - G39-
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ if a re-used lambda
probe is installed, only
coat the thread with hot
bolt paste - G 052 112
A3- ; the hot bolt paste -
G 052 112 A3- must not
get into the slots of the
probe body
❑ 55 Nm
4 - Exhaust pipe with catalytic
converter
❑ protect against shocks
and blows
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Secure decoupling ele‐
ment with transport se‐
curity - T10403-
❑ removing and installing
⇒ page 296
❑ Align exhaust system free of stress ⇒ page 299
1 - Gasket
❑ replace
2 - Nut
❑ replace
❑ Coat stud bolts of ex‐
haust manifold with hot
bolt paste - G 052 112
A3- before installing.
❑ 40 Nm
3 - Lambda probe upstream of
catalytic converter - G39-
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ if a re-used lambda
probe is installed, only
coat the thread with hot
bolt paste - G 052 112
A3- ; the hot bolt paste -
G 052 112 A3- must not
get into the slots of the
probe body
❑ 55 Nm
4 - Exhaust pipe with catalytic
converter
❑ protect against shocks
and blows
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Secure decoupling ele‐
ment with transport se‐
curity - T10403-
❑ removing and installing
⇒ page 296
❑ Align exhaust system free of stress ⇒ page 299
5 - lambda probe downstream of catalytic converter - G130-
❑ the thread of new lambda probes must be coated with assembly paste
❑ if a re-used lambda probe is installed, only coat the thread with hot bolt paste - G 052 112 A3- ; the hot
bolt paste - G 052 112 A3- must not get into the slots of the probe body
❑ 55 Nm
6 - Hanger
❑ replace if damaged
7 - Screw
❑ 23 Nm
8 - Nuts
❑ 20 Nm
9 - Tunnel bridge
10 - Retaining strap
❑ replace if damaged
11 - Rear part of exhaust system
❑ for first equipment building unit with middle part of exhaust gas system, replace individually when carrying
out repairs
❑ replace ⇒ page 298
– Unscrew the nuts -arrows- and open up the under floor trim
panel downwards on the inner side on the right.
– Unclip the cable -arrow-, remove the mounting bracket -1- and
disconnect the plug connection-2- for the lambda probe - G39/
G130- .
Vehicles with four-wheel drive
– Remove propshaft ⇒ Transmission; Rep. gr. 39.
Continued for all vehicles
Note
Note
Note
WARNING
– Push the exhaust system so far forward until the initial load
-dimension a- on the retaining strap at the middle part of the
exhaust system is 9...11 mm.
Vehicles with four-wheel drive
– Push the exhaust system so far forward until the initial load
-dimension a- on the retaining strap at the middle part of the
exhaust system is 7...9 mm.
Continued for all vehicles
– Tighten the nuts of the front clamping sleeve evenly to 23 Nm.
Align exhaust tailpipes
– Seal off exhaust tailpipes for the duration of the leak check
(e.g. with cloth or plug).
– Inspect connection points of cylinder head/exhaust manifold,
exhaust gas turbocharger/pre-exhaust pipe etc. for leaktight‐
ness by listening and visual inspection.
– Eliminate any leak found.
28 – Ignition system
1 Ignition system
Note
– Using the puller - T40039- , remove all ignition coils from the
spark plug shaft approx. 30 mm.
– Unlock the connectors from all ignition coils -arrows-, and then
remove the connectors at the same time.
Install
– Insert all ignition coils loosely into the spark plug shaft.
– Press the ignition coils -1- by hand until they lock into place on
the spark plugs.
Note
– Remove the charge air hose -A- and seal the charge air cooler
with a clean cloth.
– Unscrew bolt -1- and -4- and remove the charge-air pipe by
moving it downwards.